Inflatable case to transport a sports board and a method for making the same

ABSTRACT

An inventive case capable of transporting a sports board, such as a surfboard, snowboard or skate board or element thereof, is described. The case may include a top cushion designed to conform to a top surface of a sports board, a bottom cushion designed to conform to a bottom surface of the same sports board. Optionally or alternatively, each of the top and the bottom cushions may include a plurality of compartments which have varying cross-sectional dimensions along a length of the compartments.

RELATED APPLICATION

This Application is a US Nonprovisional Continuation-in-Part Patent Application of, and claims the benefit of the filing date of, U.S. Nonprovisional patent application Ser. No. 12/396,232, filed Mar. 2, 2009 and titled INFLATABLE CASE TO TRANSPORT A SURFBOARD AND A METHOD FOR MAKING THE SAME. THIS U.S. Nonprovisional patent application Ser. No. 12/396,232 is incorporated herein by reference in its entirety.

FIELD OF THE INVENTION

The present invention relates to a protective case designed to transport a sports board, such as a surfboard, snowboard or skateboard. More particularly, the present invention relates to a sports board case that presents varying thickness along its length and a method for making the same.

BACKGROUND OF THE INVENTION

The subject matter discussed in the background section should not be assumed to be prior art merely as a result of its mention in the background section. Similarly, a problem mentioned in the background section or associated with the subject matter of the background section should not be assumed to have been previously recognized in the prior art. The subject matter in the background section merely represents different approaches, which in and of themselves may also be inventions.

Sport boards are frequently transported inside a case from a user's home or location of storage to a use location, e.g., a ski slope, skate board park or a surfing site. Surfing and sports board use sites can be local, but may also include distant or international destinations. As a result, current designs of sports board cases attempt to protect the encased sports board from damage during transit. Specifically, prior art designs of cases attempt to protect the surfboard from being impacted by an external force (e.g., from movement of adjacent bags, applied by the loading or unloading personnel or exerted by transporting equipment).

Commonly available designs contemplate cases made from synthetic rubber foam sheet material of uniform thickness for covering the sports board. Unfortunately, they do not provide sufficient protection to the top and bottom surfaces of a sports board, e.g., a surfboard, during transit. Moreover, when not in use, these cases do not collapse or fold for easy storage.

To this end, U.S. Pat. No. 7,017,747 entitled “Protective Inflatable Surfboard Covering Device” issued to Kiger et al. offers a surfboard case design that is inflatable. Specifically, this design provides an inflatable top and an inflatable bottom cushion of uniform thickness to cover the top and bottom surfaces of a surfboard. Furthermore, this design also includes a side rail cushion having an inwardly “C-shape” that is designed to partially circumscribe the side rails.

In FIG. 1, a typical surfboard 10 having a front portion 12, a middle portion 16 and a back portion 14 is shown. Side rails 8 extend from front portion 12 to back portion 14 on both sides of surfboard 10. In U.S. Pat. No. 7,017,747, “C-shaped” side rail cushion in its inflated position will assume a concave curvature to complement or conform and embrace the generally convex structure of side rail 8.

Unfortunately, however, the prior art inflatable case design does not adequately protect the surfboard inside. With the top and bottom cushions of uniform thickness, the design does not properly protect the pronounced rise in the curvature at front portion 12 and slight rise in back portion 14 of the surfboard. In other words, in the current design an external force impacting either a top or a bottom surface of the case does not have much to travel before it strikes either the rising front or back portions of the encased surfboard. Consequently, the top and bottom surfaces of the surfboard are not adequately protected by the prior art inflatable design.

What is therefore needed is a new surfboard design that effectively protects the rising curvature at the front and back portions of the surfboard and also the top and bottom surfaces of the surfboard from an impacting external force.

This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

SUMMARY OF THE INVENTION

Toward this and other objects that are made obvious in light of the disclosure, a n inventive case capable of transporting a sports board, such as a surfboard or a skate board or element thereof, is disclosed and provided. The case may include a top cushion designed to conform to a top surface of a sports board, a bottom cushion designed to conform to a bottom surface of the same sports board. Optionally or alternatively, each of the top and the bottom cushions may include a plurality of compartments which have varying cross-sectional dimensions along a length of the compartments. One or more cushions may be filled with air, pressurized air, pressurized gas, cushioning material such as resilient and/or elastic foam, and/or liquid.

To achieve the foregoing, certain preferred embodiments of the present invention provide in one aspect a case capable of transporting a sports board. The case includes: (1) a top cushion designed to conform to a top surface of a sports board; (2) a bottom cushion designed to conform to a bottom surface of the sports board; and (3) wherein each of the top and the bottom cushions include a plurality of compartments which have varying cross-sectional dimensions along a length of the compartments. The top cushion, the bottom cushion and compartments can be made from foam like materials and/or include pressurized gas, such as ambient air.

The invented case is shaped along a length of the Y axis and presents varying widths along both an orthogonal X axis and a varying height along a mutually orthogonal Z axis to conform to and support the structure of a sports board, whereby the sports board is cushioned and the cushions of the invented case absorb force and thereby reduces force and stress delivered against the sports board. In contrast, the prior art cases are not formed to conform to and mechanically support the curved shape of a sports board. In patentable distinction, the invented cushions are shaped to both shield the sports board and resist deformation of the sports board when external force is applied against the invented case. In another patentably distinguishing aspect, when the sports board is located between the invented cushions, the invented cushions act to absorb external force, resist deformation of a curvature of the sports board and support the resting shape of the sports board.

In an alternative embodiment of the present invention, the top and bottom cushions and said plurality of compartments are inflatable and the compartments have defined therein an aperture which allows air to travel from one compartment to another compartment. The case may further include a side rail cushion that is disposed between the top cushion and the bottom cushion and is designed to be adjacent to a side rail of the surfboard when the surfboard is encased inside the case.

In certain still alternate preferred embodiments of the present invention, at a distance which equals between about 0 and about ⅓ of a length of the case and the distance measured from the front end of the case, a cross-sectional area of the compartment of the top cushion is between about 4 square inches and about 30 square inches. At a distance which equals between more than ⅓ and about ⅔ of a length of the case and the distance being measured from a front end of the case, a thickness of the inflatable compartment of the top cushion in an inflated state may be between about 6 square inches and about 30 square inches. At a distance which equals between about 0 and about ⅓ of a length of the case and the distance measured from a back end of the case, a thickness of the inflatable compartment of the top cushion in an inflated state may be between about 4 inches and about 24 inches. At a distance which equals between about 0 and about ⅓ of a length of the case and the distance being measured from a front end of the case, a thickness of the inflatable compartment of the bottom cushion in an inflated state may be between about 6 square inches and about 30 square inches. At a distance which equals between about ⅓ and about ⅔ of a length of the case and the distance measured from a front end of the case, a thickness of the inflatable compartment of the bottom cushion in an inflated state may be between about 4 square inches and about 24 square inches. At a distance which equals between about 0 and about ⅓ of a length of the case and the distance measured from a back end of said case, a thickness of the inflatable compartment of the bottom cushion in an inflated state may be between about 4 square inches and about 30 square inches.

In another aspect, the present invention provides a case capable of transporting a surfboard. The surfboard includes: (1) a top inflatable cushion designed to conform to a top surface of a surfboard in an inflated state of the top cushion; (2) a bottom inflatable cushion designed to conform to a bottom surface of the surfboard in an inflated state of the bottom cushion; and (3) wherein in an inflated state, each of the top and the bottom cushions vary in thickness along their length to protect the top surface and bottom of surfboard from being impacted from an external force when the surfboard is secured inside the case.

In alternative embodiments of the present invention, the case further includes a side rail cushion that is capable of being disposed between the top and the bottom cushions. Although the inventive case need not be inflatable, in one preferred embodiment of the invention, the case is made from inflatable components. For example, the top and the bottom cushion may be inflatable such that in an inflated state the top cushion conforms to the top surface of the surfboard and the bottom cushion conforms to the bottom surface of the surfboard and the case further includes a first valve designed to inflate the top cushion, a second valve designed to inflate the bottom cushion and a third valve designed to inflate the side rail cushion.

At a distance which equals between about 0 and about ⅓ of a length of the case and the distance measured from the front end of the case, a thickness of the inflatable compartment of the top cushion in an inflated state may be between about 2 inches and about 4 inches. At a distance which equals between more than ⅓ and about ⅔ of a length of the case and the distance measured from a front end of the case, a thickness of the inflatable compartment of the top cushion in an inflated state may be between about 2.5 inches and about 4.75 inches. At a distance which equals between about 0 and about ⅓ of a length of the case and the distance measured from a back end of the case, a thickness of the inflatable compartment of the top cushion in an inflated state may be between about 2 inches and about 4.75 inches. At a distance which equals between about 0 and about ⅓ of a length of the case and the distance measured from a front end of the case, a thickness of the inflatable compartment of the bottom cushion in an inflated state may be between about 2 inches and about 4.75 inches. At a distance which equals between about ⅓ and about ⅔ of a length of the case and the distance measured from a front end of the case, a thickness of the inflatable compartment of the bottom cushion in an inflated state may be between about 2.5 inches and about 3.5 inches. At a distance which equals between about 0 and about ⅓ of a length of the case and the distance measured from a back end of the case, a thickness of the inflatable compartment of the bottom cushion in an inflated state may be between about 2 inches and about 4.75 inches.

In yet another aspect, the present invention provides a method for manufacturing a case. The method of manufacturing includes: (1) fabricating a plurality of longitudinal inflatable compartments having varying cross-sectional areas along their lengths; and (2) adhering some of the longitudinal compartments to form a top cushion and adhering others of the longitudinal compartments to form a bottom cushion.

The method may further include: (1) fabricating a side rail cushion; and (2) joining a portion of the side rail cushion to the top cushion and another portion of the side rail cushion to the bottom cushion for forming an envelope which is capable of receiving a surfboard.

In one yet alternate embodiment of the present invention, the method of fabricating the invented case includes extruding, casting and/or welding. The process of adhering components of the invented case may preferably be carried out by heat welding or high frequency welding in certain other alternate embodiments of the present invention. It is understood that high frequency welding is a welding process well known in the art in which a heat source may be used to melt the joining surfaces that is obtained from or provided by high-frequency alternating current resistance heating.

In certain additional embodiments of the inventive process, the step of fabricating the plurality of longitudinal compartments includes forming inflatable compartment which include an aperture in each of the plurality of longitudinal compartments. The step of fabricating may also include a first valve for providing air inside the top cushion, a second valve for providing air inside the bottom cushion and a third valve for providing air inside the side rail cushion.

BRIEF DESCRIPTION OF THE FIGURES

These, and further features of the invention, may be better understood with reference to the accompanying specification and drawings depicting the preferred embodiment, in which:

FIG. 1 is a side view of a surfboard.

FIG. 2 is a side-sectional view of a surfboard inside a surfboard case, according to one embodiment of the present invention.

FIG. 3 is side-sectional view of a surfboard case as shown in FIG. 2, but without a surfboard inside the case.

FIG. 4A shows a top view of a top cushion which is one component of the surfboard shown in FIG. 3.

FIG. 4B shows a top view of a bottom cushion which is another component of the surfboard shown in FIG. 3.

FIG. 5 shows a top perspective view of a top cushion attached to side rails according to one embodiment of the present invention.

FIG. 6A shows an exemplar inflatable compartment in top cushion as shown in FIG. 4A.

FIG. 6B shows an exemplar inflatable compartment in bottom cushion as shown in FIG. 4B.

FIG. 7A is a side view of the surfboard of FIG. 1 placed within a second invented case comprising an upper foam cushion and a lower foam cushion.

FIG. 7B is a side view of the second invented case of FIG. 7A with the surfboard of FIG. 1 removed.

FIG. 7C is a top view of the surfboard of FIG. 1 positioned on top of, and resting upon, the bottom foam cushion of FIG. 7A.

FIG. 8A is a top view of an internal bottom fabric layer of a third inflatable bottom cushion of a third invented case.

FIG. 8B is a top view of an outer top fabric layer of a third top cushion of the third invented case.

FIG. 9A is a side view of four bottom cushion fabric layers of in place within a high frequency heat welding system.

FIG. 9B is a side view of four top cushion fabric layers of in place within the high frequency heat welding system of FIG. 9A.

FIG. 10 is a process chart of a fabrication of the bottom cushion of FIG. 9A.

FIG. 11 is a process chart of a fabrication of the top cushion of FIG. 9B.

FIG. 12 is a schematic illustration of a computer aided design and manufacturing communications network

FIG. 13A is a top view of the bottom inflatable cushion of FIG. 9A presented with exemplary dimensions.

FIG. 13B is a side view of the bottom inflatable cushion of FIG. 9A dimensioned in accordance with FIG. 13A.

FIG. 13C is a cut-away front view of the bottom inflatable cushion of FIG. 9A dimensioned in accordance with FIG. 13A and FIG. 13B.

FIG. 14A is a top view of the top inflatable cushion of FIG. 9B presented with exemplary dimensions.

FIG. 14B is a side view of the top inflatable cushion of FIG. 9B dimensioned in accordance with FIG. 14A.

FIG. 14C is a cut-away front view of the top inflatable cushion of FIG. 9B dimensioned in accordance with FIG. 14A and FIG. 14B.

FIG. 15 is a representation of a third weld pattern W.3 that creates two separate air compartments that may reside within a cushion of FIG. 8A and FIG. 8B.

DESCRIPTION

It is to be understood that this invention is not limited to particular aspects of the present invention described, as such may, of course, vary. It is also to be understood that the terminology used herein is for the purpose of describing particular aspects only, and is not intended to be limiting, since the scope of the present invention will be limited only by the appended claims.

Methods recited herein may be carried out in any order of the recited events which is logically possible, as well as the recited order of events.

Where a range of values is provided herein, it is understood that each intervening value, to the tenth of the unit of the lower limit unless the context clearly dictates otherwise, between the upper and lower limit of that range and any other stated or intervening value in that stated range, is encompassed within the invention. The upper and lower limits of these smaller ranges may independently be included in the smaller ranges and are also encompassed within the invention, subject to any specifically excluded limit in the stated range. Where the stated range includes one or both of the limits ranges excluding either or both of those included limits are also included in the invention.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although any methods and materials similar or equivalent to those described herein can also be used in the practice or testing of the present invention, the methods and materials are now described.

It must be noted that as used herein and in the appended claims, the singular forms “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise. It is further noted that the claims may be drafted to exclude any optional element. As such, this statement is intended to serve as antecedent basis for use of such exclusive terminology as “solely,” “only” and the like in connection with the recitation of claim elements, or use of a “negative” limitation.

The present invention provides inventive designs for a sports board case and methods for making the same. Prior art sports board case designs provide cushions of uniform thickness. In sharp contrast, the present invention offers sports board case designs that provide cushions of non-uniform thickness. In the present invention, the sports board case can be made from foam like material, such as but not limited to polyurethane foam or from an inflatable material, such as but not limited to aromatic polyether polyurethane film or fabric, nylon, and/or polyester. Given that an inflatable design is easy to transport, it represents a preferred embodiment of the present invention.

FIG. 2 shows a case 100, in an inflated state, according to one embodiment of the present invention. Case 100 encases a surfboard 110, which is similar to surfboard 10 of FIG. 1. As shown in FIG. 2, case 100 includes a top cushion 102 and a bottom cushion 104. Top cushion 102 is designed to conform to a top surface of surfboard 110 and bottom cushion 104 is designed to conform to a bottom surface of surfboard 110. In an inflated state, each of top cushion 102 and bottom cushion 104 vary in thickness along their length. Those skilled in the art will recognize that a case made from foam like material will have cushions which are also made from foam like material and similarly vary in thickness along the length of the cushions to conform to the different surfaces of the surfboard.

The case 100 is shaped along a length of the Y axis and presents varying widths along both an orthogonal X axis and a varying height along a mutually orthogonal Z axis to conform to and support the structure of the surfboard 10, whereby the surfboard 10 is cushioned and the invented cushions 102 & 104 absorb force and thereby reduces force and stress delivered against the surfboard 10. In contrast, the prior art cases are not formed to conform to and support the curved shape of the surfboard 10. In patentable distinction, the invented cushions 102 & 104 are shaped to both shield the surfboard 10 and resist deformation of the surfboard 10 when external force is applied against the invented case 100. In another patentably distinguishing aspect, when the surfboard 10 is located between the invented cushions 102 & 104, the cushions 102 & 104 act to absorb external force, resist deformation of the surfboard curvature and support the resting shape of the surfboard 10.

FIG. 3 shows a case 100′ in an inflated state and which is similar to case 100 of FIG. 2, except it does not include surfboard 110. As shown in FIG. 3, the length of each of top cushion 102 and bottom cushion 104 extends from a front tip located at a front portion 112 to a back end located at a back portion 114. At back portion 114, which approximately equals a distance between about 0 and about ⅓ the length of the case and is measured from the back end of case 100′, top cushion 102 has a thickness that ranges from between about 2 inches to about 4 inches. At a middle portion 116, which approximately equals a distance between more than ⅓ and about ⅔ the length of the case and is measured from the back end of case, top cushion 102 has a thickness that ranges from between about 2.5 inches to about 4.75 inches. At a front portion 112, which approximately equals a distance between about 0 and about ⅓ the length of the case and is measured from the front tip of case 100′, top cushion 102 has a thickness that ranges from between about 2 inches to about 4.75 inches.

Similarly, at back portion 114, bottom cushion 102 has a thickness that ranges from between about 2 inches to about 4.75 inches. At a middle portion 116, bottom top cushion 102 has a thickness of between about 2.5 inches to about 3.5 inches. At a front portion 112, bottom cushion 102 has a thickness that ranges from between about 2.5 inches to about 4.5 inches.

FIG. 4A shows that top cushion 102 includes a plurality of longitudinally extended inflatable compartments 106, which are communicatively coupled to each other through apertures 120 and 122. Similarly, FIG. 4B shows that bottom cushion 104 includes a plurality of longitudinally extended inflatable compartments 108, which are communicatively coupled to each other through apertures 124 and 126. Each of top cushion 102 and bottom cushion come fitted with at least one valve (not shown to simplify illustration) which allows inflation of compartments with air.

FIG. 6A shows a lengthwise cross-sectional view of one inflatable compartment which is used to manufacture top cushion 102. According to this figure, a length of an inflatable compartment 106 extends from a back end located at a back portion 114′ through a middle portion 116′ to a front tip located at a front portion 112′, At back portion 114′, which approximately equals a distance between about 0 (i.e. back end) and about ⅓ the length of compartment 106 and is measured from the back end of compartment 106, compartment 106 has a cross-sectional area that ranges from between about 4 square inches to about 24 square inches. At a middle portion 116′, which approximately equals a distance between more than ⅓ and about ⅔ the length of the compartment 106 and is measured from the back end of compartment 106, compartment 106 has a cross-sectional area that ranges between about 6 square inches to about 30 square inches. At a front portion 112′, which approximately equals a distance between about 0 and about ⅓ the length of compartment and is measured from the front tip of compartment 106, compartment 106 has a cross-sectional area that ranges from between about 4 square inches to about 30 square inches.

Similarly, at back portion 114″, bottom cushion 108 has a cross-sectional area that ranges from between about 4 square inches to about 30 square inches. At a middle portion 116″, bottom cushion 108 has a cross-sectional area that ranges from between about 4 square inches to about 24 square inches. At a front portion 112″, bottom cushion 102 has a cross-sectional area that ranges from between about 6 square inches to about 30 square inches.

Those skilled in the art will recognize that although cross-sectional areas and thickness values for the cushions and compartments that make up the inventive case are described for an inflatable design, such values equally apply to non-inflatable designs where the cushion and the compartments are made from foam like material.

In accordance with one embodiment of the present invention, a process of manufacturing a surfboard case, such as the one shown in FIG. 2, includes fabricating a plurality of inflatable compartments (e.g., shown in FIGS. 6A and 6B). More preferably, these compartments are formed by either extrusion or casting such that when the compartments are inflated, their cross-sectional dimensions vary across the length of the compartments. Inflatable compartments will have apertures defined therein allowing them to be communicatively coupled to each other, allowing air to flow in and out of the various chamber during inflation and deflation of the cushions. In alternative embodiments of the present invention, where compartments are made from foam like material, similarly casting or extrusion is used during fabrication.

Regardless of whether an inflatable or non-inflatable design is being implemented, certain of the compartments will adhere to form a top cushion as shown in FIG. 4A and other compartments will adhere to form a bottom cushion as shown in FIG. 4B. The adhering process can include any technique well known in the art, but heat welding is a more preferred technique. Those skilled in the art will recognize that each of top cushion and bottom cushion will be fitted with a valve which allows air to be introduced inside and inflate them.

Next, a side rail cushion 118 as shown in FIG. 5 is fabricated according to well known techniques. The side rail cushion is preferably inflatable and attaches at between top cushion 102 and bottom cushion (not shown to simplify illustration in FIG. 5) to form an envelope with an opening which allows a surfboard to enter case 100 (as shown in FIG. 2).

FIG. 7A is a side view of the surfboard 10 placed within a second invented case 700 comprising an upper foam cushion 702 and a lower foam cushion 704. The cushions may be or comprise a high resiliency foam, such as a polyurethane foam preferably having a density in the range of from six kilograms per cubic meter to 100 kilograms per cubic meter. The upper foam cushion 702 and the lower foam cushion 704 are sized and shaped to substantively contact and support the surfboard 10. The upper foam cushion 702 and the lower foam cushion 704 preferably maintain direct contact with greater than 80 percent of an outer surface area of the surfboard 10 when positioned to protect the surfboard 10. More preferably, upper foam cushion 702 and the lower foam cushion 704 preferably maintain direct contact with greater than 90 percent of an outer surface area of the surfboard 10 when positioned to protect the surfboard 10.

FIG. 7B is a side view of the second invented case 700 with the surfboard 10 removed.

FIG. 7C is a top view of the surfboard 10 positioned on top of, and resting upon, the lower foam cushion 704.

FIG. 8A is a top view of an internal bottom fabric layer 800A of a third inflatable bottom cushion 802 of a third invented case 804. The internal bottom fabric layer 800A may be or comprise nylon, polyester or other suitable material known in the art. The internal bottom fabric layer 800A is shown in FIG. 8A to form a bottom edge outline 802E and prior to being incorporated by heat welding in accordance with a bottom weld pattern W.1 to form the inflatable bottom cushion 802 of the third invented case 804. A plurality of apertures A are provided by the bottom weld pattern W.1 to allow air or gas to flow freely within the bottom cushion 802. An external aperture A1 provides a channel that allows air or gas to flow in and out from between layers 800B & 800C.

FIG. 8B is a top view of an outer top cushion fabric layer 806A of a third top cushion 808 of the third invented case 804. The outer top fabric layer 806A may be or comprise nylon, polyester or other suitable material known in the art. The outer top fabric layer 806A is shown in FIG. 8B to form a top edge outline 808E and prior to being incorporated by heat welding in accordance with a top weld pattern W.2 to form the inflatable top cushion 808 of the third invented case 804. A plurality of apertures A are provided by the top weld pattern W.2 to allow air or gas to flow freely within the top cushion 808. An external aperture A1 provides a channel that allows air or gas to flow in and out from between layers 806B & 806C.

FIG. 9A is a side view of four bottom cushion fabric layers 800A-800D in place within a high frequency heat welding system 900 and electrically heated by two bottom cushion mold elements 902 & 904. The two bottom cushion flexible fabric layers 800B & 800C may be or comprise a suitable inflatable and expandable fabric or material known in the art, such as but not limited to aromatic polyether polyurethane. The internal bottom fabric layer 800A and the external bottom fabric layer 800D may be or comprise a suitable rugged fabric or material known in the art, such as but not limited nylon or polyester. It is preferable that all four bottom cushion fabric layers 800A-800D are substantively shaped to conform to the bottom edge outline 800E within plus or minus five percent deviation by surface area.

FIG. 9B is a side view of four top cushion fabric layers 806A-806D in place within the high frequency heat welding system 900 and electrically heated by two top cushion mold elements 906 & 908. The two top cushion flexible fabric layers 806B & 806C may be or comprise a suitable inflatable and expandable fabric or material known in the art, such as but not limited to aromatic polyether polyurethane. The outer top cushion fabric layer 806A and the internal top cushion fabric layer 806D may be or comprise a suitable rugged fabric or material known in the art, such as but not limited nylon or polyester. It is preferable that all four top cushion fabric layers 806A-806D are substantively shaped to conform to the top edge outline 808E within plus or minus five percent deviation by surface area.

FIG. 10 is a process chart of a fabrication of the bottom cushion 800. In step 1002 a bottom edge outline 800E is selected or generated. In step 1004 the bottom cushion weld pattern W.1 is generated and represented in a first record of digital medium. The bottom weld molds 902 & 904 are then formed from the first record in step 1006. The bottom weld molds 902 & 904 are then inserted into the heat welding system 900 in step 1008.

In step 1010 the four bottom cushion fabric layers 800A-800D are shaped to substantively conform to the bottom edge outline 800E. In step 1012 the four bottom cushion fabric layers 800A-800D are then positioned to preferably mutually lay within the bottom edge 800E outline and layered as shown in FIG. 9A.

The four bottom cushion fabric layers 800A-800D are then positioned relative to the high frequency welding system 900 in step 1014 to enable heat welding of the four bottom cushion fabric layers 800A-800D to form the bottom cushion 802 by imposing a bottom pattern W.1 of heat welds. Inflation channel fixtures 800F are then attached to the bottom cushion 802 at external channel A1 in step 1016 to enable selection inflation and deflation of the bottom cushion 802. The bottom cushion 802 is then inflated in step 1018 by introduction of pressurized gas, e.g., ambient air or gas from a pressurized tank, in between the bottom cushion flexible fabric layers 800B & 800C. The bottom cushion 800 may then be inserted into an external bag BAG and brought into contact with the surfboard 10 in step 1020.

FIG. 11 is a process chart of a fabrication of the bottom cushion 800. In step 1102 a top edge outline 808E is selected or generated. In step 1104 the top cushion weld pattern W.2 is generated and represented in a second record of digital medium. The top weld molds 906 & 908 are then formed from the second record in step 1106. The top weld molds 906 & 908 are then inserted into the heat welding system 900 in step 1108.

In step 1110 the four top cushion fabric layers 806A-806D are shaped to substantively conform to the top edge outline 808E. In step 1112 the four top cushion fabric layers 806A-806D are then positioned to preferably lie within the top edge 808E outline and layered as shown in FIG. 9B.

The four top cushion fabric layers 806A-806D are then positioned relative to the high frequency welding system 900 in step 1114 to enable heat welding of the four top cushion fabric layers 806A-806D to form the top cushion 808 by imposing the top pattern W.2 of heat welds. Inflation channel fixtures 800F are then attached to the top cushion 808 at external apertures A1 in step 1116 to enable selection inflation and deflation of the top cushion 808. The top cushion 808 is then inflated in step 1118 by introduction of pressurized gas, e.g., ambient air or gas from a pressurized tank, in between the top cushion flexible fabric layers 806B & 806C. The top cushion 808 may then be inserted into an external bag BAG and brought into contact with the surfboard 10 in step 1120.

FIG. 12 is a schematic illustration of a computer aided design and manufacturing communications network 1200 (“network: 1200) that may be used to at least partly enable the process of FIG. 10 and FIG. 11. The network 1200 includes the Internet 1204 and a telephony network 1204, a computer aided design system 1206, a mold maker system 1208, the welding system 900 and a plurality of database servers 1210. The computer aided design system 1206, the mold maker system 1208, the welding system 900 and the plurality of database servers 1210 are bi-directionally communicatively coupled by the Internet 1204. A user applies the CAD system 1206 to generate electronic pattern documents DOC.1 that define the mold patterns W.1 & W.2 by means of a first CAD software CAD.1, and then transfers the electronic pattern documents DOC.1 to the mold maker system 1208. The mold maker system 1208 applies the electronic pattern documents DOC.1 to generate the weld molds 902-908 as per steps 1006 and 1106 respectively. A user further generates electronic weld documents DOC.2 by means of a second CAD software CAD.2 and the CAD system 1206 that enables the welding system 900 to form the cushions 802 and 808. The CAD system 1206 transfers the electronic pattern documents DOC.2 to the welding system 900. The welding system 900 applies the electronic weld documents DOC.2 to generate the cushions 802 & 808 as per steps 1014 and 1114 respectively.

FIG. 13A is a top view of an exemplary dimensioning of the bottom inflatable cushion 802 that presents the bottom weld pattern W.1 comprising a plurality of bottom weld walls W.1W as formed by the welding system 900. The bottom weld walls W.1W form a plurality of inflatable compartments W.1C. It is understood that the dimensions of the compartments W.1C and cushions 802 & 808 shown in FIGS. 13A through 14C are exemplary and are offered for illustration purposes and not limiting the scope of either the invention or the claims.

FIG. 13B is a side view of the bottom inflatable cushion 802 dimensioned in accordance with FIG. 13A.

FIG. 13C is a cut-away front view of the bottom inflatable cushion 802 dimensioned in accordance with FIG. 13A and FIG. 13B.

FIG. 14A is a top view of an exemplary dimensioning of the top inflatable cushion 808 that presents the top weld pattern W.2 comprising a plurality of top weld walls W.2W as formed by the welding system 900. The top weld walls W.2W form a plurality of inflatable compartments W.2C. It is understood that the dimensions of the compartments W.2C & W.1C and cushions 802 & 808 shown in FIGS. 13A through 14C are exemplary and are offered for illustration purposes and not limiting the scope of either the invention or the claims.

FIG. 14B is a side view of the top inflatable cushion 808 dimensioned in accordance with FIG. 14A.

FIG. 14C is a cut-away front view of the top inflatable cushion 808 dimensioned in accordance with FIG. 14A and FIG. 14B.

Each compartment W.1C is shaped along a length of the Y axis and presents varying widths along both an orthogonal X axis and a varying height along a mutually orthogonal Z axis to conform to and support the structure of the surfboard 10, whereby the surfboard 10 is cushioned and the inflatable cushion 802 & 808 absorb force and thereby reduces force and stress delivered against the surfboard 10. In contrast, the prior art cases are not formed to conform to and support the curved shape of the surfboard 10. In patentable distinction, the compartments W.1C of the invented cushions 802 & 808 are shaped to both shield the surfboard 10 and resist deformation of the surfboard 10 when external force is applied against the invented case 804. In another patentably distinguishing aspect, when the surfboard 10 is located between the inflated cushions 802 & 808, the cushions 802 & 808 act to absorb external force, resist deformation of the surfboard curvature and support the resting shape of the surfboard 10.

FIG. 15 is a representation of a third weld pattern W.3 that creates two separate air compartments 1500 & 1502 that may reside within a cushion 802 or 808.

The foregoing disclosures and statements are illustrative only of the Present Invention, and are not intended to limit or define the scope of the Present Invention. The above description is intended to be illustrative, and not restrictive. Although certain examples have been described in terms. For example, the inventive case has been explained in terms of a surfboard, but can be used to transport any kind of board used for water sports, skiing etc. Although the examples given include many specificities, they are intended as illustrative of only certain possible configurations or aspects of the Present Invention. The examples given should only be interpreted as illustrations of some of the preferred configurations or aspects of the Present Invention, and the full scope of the Present Invention should be determined by the appended claims and their legal equivalents. Those skilled in the art will appreciate that various adaptations and modifications of the just-described preferred embodiments can be configured without departing from the scope and spirit of the Present Invention. Therefore, it is to be understood that the Present Invention may be practiced other than as specifically described herein. The scope of the present invention as disclosed and claimed should, therefore, be determined with reference to the knowledge of one skilled in the art and in light of the disclosures presented above. 

What is claimed is:
 1. A case capable of transporting a surfboard, comprising: a top cushion designed to conform to a top surface of a surfboard; a bottom cushion designed to conform to a bottom surface of the surfboard, wherein each of said top and said bottom cushions include a plurality of compartments which have varying cross-sectional dimensions along a length of said compartments.
 2. The surfboard case of claim 1, wherein said top and bottom cushions and said plurality of compartments are inflatable and said compartments have defined therein an aperture which allows air to travel from one compartment to another compartment.
 3. The surfboard case of claim 1, further comprising a side rail cushion that is disposed between said top cushion and said bottom cushion and is designed to be adjacent to a side rail of said surfboard when said surfboard is encased inside said case.
 4. The surfboard case of claim 2, wherein at a distance which equals between about 0 and about ⅓ of a length of said case and said distance measured from the front end of said case, a cross-sectional area of said compartment in an inflated state of said top cushion is between about 4 square inches and about 30 square inches.
 5. The surfboard case of claim 2, wherein at a distance which equals between more than ⅓ and about ⅔ of a length of said case and said distance measured from a front end of said case, a thickness of said compartment of said top cushion in an inflated state is between about 6 square inches and about 30 square inches.
 6. The surfboard case of claim 2, wherein at a distance which equals between about 0 and about ⅓ of a length of said case and said distance measured from a back end of said case, a thickness of said compartment of said top cushion in an inflated state is between about 4 inches and about 24 inches.
 7. The surfboard case of claim 2, wherein at a distance which equals between about 0 and about ⅓ of a length of said case and said distance measured from a front end of said case, a thickness of said compartment of said bottom cushion in an inflated state is between about 6 square inches and about 30 square inches.
 8. The surfboard case of claim 2, wherein at a distance which equals between about ⅓ and about ⅔ of a length of said case and said distance measured from a front end of said case, a thickness of said compartment of said bottom cushion in an inflated state is between about 4 square inches and about 24 square inches.
 9. The surfboard case of claim 2, wherein at a distance which equals between about 0 and about ⅓ of a length of said case and said distance measured from a back end of said case, a thickness of said compartment of said bottom cushion in an inflated state is between about 4 square inches and about 30 square inches.
 10. A case capable of transporting a surfboard, comprising: a top inflatable cushion designed to conform to a top surface of a surfboard in an inflated state of said top cushion; a bottom inflatable cushion designed to conform to a bottom surface of the surfboard in an inflated state of said bottom cushion; wherein in an inflated state, each of said top and said bottom cushions vary in thickness along their length to protect said top surface and bottom of surfboard from being impacted from an external force when said surfboard is secured inside said case.
 11. The case of claim 10, further comprising a side rail cushion that is capable of being disposed between said top and said bottom cushions.
 12. The case of claim 11, wherein said top and said bottom cushion are inflatable such that in an inflated state said top cushion conforms to said to top surface of said surfboard and said bottom cushion conforms to said bottom surface of said surfboard and said case further comprising a first valve designed to inflate said top cushion, a second valve designed to inflate said bottom cushion and a third valve designed to inflate said side rail cushion.
 13. The surfboard case of claim 12, wherein at a distance which equals between about 0 and about ⅓ of a length of said case and said distance measured from the front end of said case, a thickness of said compartment of said top cushion in an inflated state is between about 2 inches and about 4 inches.
 14. The surfboard case of claim 12, wherein at a distance which equals between more than ⅓ and about ⅔ of a length of said case and said distance measured from a front end of said case, a thickness of said inflatable compartment of said top cushion in an inflated state is between about 2.5 inches and about 4.75 inches.
 15. The surfboard case of claim 12, wherein at a distance which equals between about 0 and about ⅓ of a length of said case and said distance measured from a back end of said case, a thickness of said inflatable compartment of said top cushion in an inflated state is between about 2 inches and about 4.75 inches.
 16. The surfboard case of claim 12, wherein at a distance which equals between about 0 and about ⅓ of a length of said case and said distance measured from a front end of said case, a thickness of said inflatable compartment of said bottom cushion in an inflated state is between about 2 inches and about 4.75 inches.
 17. The surfboard case of claim 12, wherein at a distance which equals between about ⅓ and about ⅔ of a length of said case and said distance measured from a front end of said case, a thickness of said inflatable compartment of said bottom cushion in an inflated state is between about 2.5 inches and about 3.5 inches.
 18. The surfboard case of claim 12, wherein at a distance which equals between about 0 and about ⅓ of a length of said case and said distance measured from a back end of said case, a thickness of said inflatable compartment of said bottom cushion in an inflated state is between about 2 inches and about 4.75 inches.
 19. A method for manufacturing a case, comprising: fabricating a plurality of longitudinal inflatable compartments having varying cross-sectional areas along their lengths; and adhering some of said longitudinal compartments to form a top cushion and adhering others of said longitudinal compartments to form a bottom cushion.
 20. The method of claim 19, wherein said adhering includes heat welding. 